Hermetic electrical connector

ABSTRACT

A hermetic pressure connector which provides a pressure-tight, electrically conductive connection through a hole in a bulkhead. The connector includes a transverse support member having a high pressure side and an opposite low pressure side. A passage extends through the transverse support member between the opposite sides. A conductor pin having an axial portion extends through the passage. An insulating sleeve surrounds at least the axial portion of the conductor pin, thereby electrically insulating the transverse support member from the conductor pin. A molded connected body surrounds at least a central portion of the conductor pin at least at one of the high and low pressure sides to thereby mechanically support the conductor pin in the passage. The molded connector body is directly sealingly engaged with the conductor pin, the insulating sleeve and the transverse support member. The insulating sleeve may be formed as a two-piece insert that includes a ceramic piece on the high pressure side and a piece formed of polymeric material on the low pressure side.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of application Ser. No. 11/068,140,filed Feb. 28, 2005, now U.S. Pat. No. 7,249,971, entitled “HermeticElectrical Connector” and claims the benefit of priority under 35 U.S.C.§ 119(e) from U.S. Provisional Patent Application No. 60/548,618 filedFeb. 27, 2004, the entire subject matters of which are herebyincorporated herein by reference.

BACKGROUND OF THE INVENTION

This invention relates to electrical connectors and, more particularly,to hermetically sealed electrical connectors for use in passingelectrical conductors through a bulkhead while simultaneously isolatinghigh pressure on one side of the bulkhead from low pressure on the otherside of the bulkhead.

Various structures have been developed as electrical connectors to allowready attachment and detachment of wires between electrical devices.Many electrical connectors include a plug and a receptacle. The plugincludes one or more electrically conductive male contacts or pins, andthe receptacle includes a like number of female electrically conductivecontacts. Either the male contacts, the female contacts, or both arepermanently electrically connected to wires or leads. Either the plug orthe receptacle is mounted in a wall or secure structure, such as abulkhead, although in some instances both the plug and the receptaclewill be connected to one another independently of any other structure.Electrical connection is easily achieved by pushing the male contacts onthe plug into the receptacle (or vice versa), and disconnection isachieved by pulling the plug out of the receptacle. Such components areoften mated with other components such as socket blocks or sealedconnector boot assemblies. Where the connector is situated within abulkhead, the connector is essentially the main component and attachmentto each of the exposed ends of the conductors of the connector could beaccomplished either by direct and permanent connection to egress leadsor by removable connections as described above.

Generally the electrically conductive contacts of both the plug and thereceptacle are supported in a dimensionally stable, electricallyinsulative material surrounded by a metallic housing or similar rigidstructure. This insulator electrically isolates the various contacts andfurther maintains alignment of the contacts for ready connection anddisconnection and to maintain electrical isolation from the housing andthe bulkhead, if any. Metal housings are often used to provide greatersupport for the connector, and are particularly useful in settings wherehigh forces will be encountered by the connector. Notwithstanding theadvantages of using housings, such structures can have significantdrawbacks, including the cost of making the housings and incorporatingthe housings into the connector.

Moreover, in certain settings it is desired that either the plug orreceptacle be “hermetically” sealed, i.e., sealed so as to preventegress of fluids across a boundary created by the seal. Hermeticallysealed connectors are particularly useful when it is necessary tomaintain a controlled environment on one or both sides of the connector,and specifically where the integrity of electrical power or anelectrical signal must be maintained between a region of relatively highpressure from a region of relatively low pressure. Hermetic connectorshave particularly great utility in the field of downhole well tools usedfor subterranean drilling operations, where temperatures can exceed 500degrees Fahrenheit and pressures can reach above 30,000 pounds persquare inch. In such settings, various electronic components are housedwithin the downhole well tools and such electronics generally aredesigned to operate at atmospheric pressure, thereby requiring effectiveisolation between the high pressures of the ambient environment withinthe well and the low or atmospheric pressure within electronics modules.Additionally, it is generally required that electrical leads pass fromwithin the sealed well, at high pressure, to the ambient conditionsabove ground to provide for control and monitoring within the well.Accordingly, for both conditions, hermetic connectors are essential tothe functioning of downhole well tools.

Hermetic connectors for high temperature and high pressure service areknown in the prior art, for example the invention described by U.S. Pat.No. 6,582,251 (Burke et al., “the '251 patent”). The invention of the'251 patent eliminates use of a housing in the construction of anelectrical connector thereby eliminating a potential leak path betweenthe insulator and the housing. Similar to the present invention, theinvention of the '251 patent comprises electrical conductors embedded inpolymeric materials. One limitation of the invention of the '251 patentis that at extreme pressures and temperatures (e.g. 30,000 psi and 500deg F.), the connector polymeric materials are subject to creep andmovement of the conductor pins can subsequently occur, resulting inunacceptable levels of reliability of the '251 patent connector at theseextreme conditions.

The connector of the present invention provides improved reliability atextreme pressure and temperature conditions, while preventing pressureor electrical leakage. It can be used in a high temperature environmentwherein high pressure differential exists and there is a need to protectelectronics or other electrical or mechanical assemblies from exposureto undesirable higher or lower pressures than those at which they weredesigned to operate, and where electrical power or signals must bepassed across the boundary between high and low pressure.

SUMMARY OF THE INVENTION

Briefly stated, the present invention is directed to a hermetic pressureconnector for providing a pressure-tight, electrically conductiveconnection through a hole in a bulkhead. The connector includes atransverse support member having a high pressure side and an oppositelow pressure side. A passage extends through the transverse supportmember between the opposite sides. A conductor pin having an axialportion extends through the passage. An insulating sleeve surrounds atleast the axial portion of the conductor pin, thereby electricallyinsulating the transverse support member from the conductor pin. Amolded connector body surrounds at least a central portion of theconductor pin at least at one of the high and low pressure sides tothereby mechanically support the conductor pin in the passage. Themolded connector body is directly sealingly engaged with the conductorpin, the insulating sleeve and the transverse support member.

Briefly stated, in another aspect, the present invention is directed toa hermetic pressure connector for providing a pressure-tight,electrically conductive connection through a hole in a bulkhead. Theconnector includes a transverse support member with a passage extendingthrough the transverse support member. A conductor pin having an axialportion extends through the passage. A molded connector body surroundsat least a central portion of the conductor pin to thereby mechanicallysupport the conductor pin in the passage. The molded connector body isdirectly sealingly engaged with the conductor pin and the transversesupport member. A dovetail retention feature interlocks the transversesupport member to the molded connector body.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofthe invention, will be better understood when read in conjunction withthe appended drawings. For the purpose of illustrating the invention,there are shown in the drawings embodiments which are presentlypreferred. It should be understood, however, that the invention is notlimited to the precise arrangements and instrumentalities shown.

In the drawings:

FIG. 1 is a side view, shown partially in cross section, of a hermeticpressure connector installed within a bulkhead, in accordance with afirst preferred embodiment of the present invention;

FIG. 2 is a side view, shown partially in cross section, of a hermeticpressure connector installed within a bulkhead, in accordance with asecond preferred embodiment of the present invention;

FIG. 3 is a side view, shown partially in cross section, of a hermeticpressure connector installed within a bulkhead, in accordance with athird preferred embodiment of the present invention;

FIG. 4 is a side view, shown partially in cross section, of a hermeticpressure connector installed within a bulkhead, in accordance with afourth preferred embodiment of the present invention; and

FIGS. 5A, 5B and 5C are side views, shown partially in cross section, offirst, second and third embodiments of coaxial connector subassembliesin accordance with the present invention, with the third preferredembodiment coaxial connector subassembly shown in FIG. 5C installed in acombination coaxial and pin hermetic connector installed within abulkhead, in accordance with a fifth preferred embodiment electricalconnector of the present invention.

FIG. 6 is a side view, shown partially in cross-section, of a hermeticpressure connector installed within a bulkhead, in accordance with asixth preferred embodiment of the present invention;

FIG. 7 is a side view, shown partially in cross-section, of a hermeticpressure connector installed within a bulkhead, in accordance with aseventh preferred embodiment of the present invention;

FIG. 8 is a side view, shown partially in cross-section, of a hermeticpressure connector installed within a bulkhead, in accordance with aneighth preferred embodiment of the present invention;

FIG. 9 is a side view, shown partially in cross-section, of a hermeticpressure connector installed within a bulkhead, in accordance with aninth preferred embodiment of the present invention;

FIG. 10 is a side view, shown partially in cross-section, of a hermeticpressure connector installed within a bulkhead, in accordance with atenth preferred embodiment of the present invention;

FIG. 11 is a side view, shown partially in cross-section, of a hermeticpressure connector installed within a bulkhead, in accordance with aneleventh preferred embodiment of the present invention; and

FIG. 12 is a side view, shown partially in cross-section, of a hermeticpressure connector installed within a bulkhead, in accordance with atwelfth preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Certain terminology is used in the following description for convenienceonly and is not limiting. The words “right”, “left”, “upper” and “lower”designate directions in the drawings to which reference is made. Theterminology includes the words above specifically mentioned, derivativesthereof, and words of similar import.

Referring to the drawings, wherein like reference numerals are used todesignate the same components throughout the figures, shown in FIGS.1-12 are first through twelfth presently preferred embodiments of ahermetic pressure connector having enhanced reliability and performanceat elevated temperature and pressure conditions. With particularreference to FIG. 1, a first embodiment electrical connector 10 is showninstalled in a bulkhead 12, such as would be commonly found in awellbore tool apparatus of the type well-known to those of ordinaryskill in the subterranean drilling art. It will be recognized by thoseof ordinary skill in the art that the present invention need not belimited in application to the wellbore tool apparatus, but may haveapplication in any situation wherein a difference in environmentalconditions exists across a boundary, and it is desired to passelectrical current across the boundary.

The electrical connector 10 includes a plurality of conductor pins 20,set within a molded connector body 30. The electrical connector 10further includes a transverse support member 40 having a plurality ofpassages 42 through which the plurality of pins 20 separately pass. Eachconductor pin 20 is surrounded by an insulating sleeve 50 whichseparates each conductor pin 20 from the support member 40. An outercircumference of the support member 40 seats against a pressure bearingledge 14 to transfer load from the connector body 30 and conductor pins20 to the bulkhead when the connector 10 is installed in the bulkhead12.

The conductor pins 20 each have a high pressure end 20 a and a lowpressure end 20 b. Each conductor pin 20 is provided with at least oneand preferably a plurality of circumferential grooves 22 and a shoulder24. The shoulder 24 bears against a base portion 52 of the insulatingsleeve 50 to transfer the differential pressure load imposed on theconductor pin 20 from the high pressure end 20 a to the low pressure end20 b. The differential pressure load is reacted from the shoulder 24 tothe insulating sleeve 50 to the support member 40 to the bulkhead 12.The transverse support member 40 may be permanently joined to thebulkhead 12 by using a low temperature welding technique like laser orelectron beam welding or by machined features like a dovetail whichingress of plastic during molding will subsequently retain.

The conductor pins 20 are preferably constructed from beryllium copperalloy, UNS C17300, available from Brush Wellman Inc., located inCleveland, Ohio, but numerous other conductive metallic materials canalso be used, including 17-4 PH stainless steel, Inconel X750, Inconel625, brass and other copper alloys, stainless steel, etc.

The transverse support member 40 is preferably made from a metallicmaterial, and more preferably from martensitic, precipitation hardenedstainless steel alloy UNS S17400, commonly referred to as 17-4 SS,available from Earl M. Jorgensen Inc., located in Houston, Tex. The 17-4SS material is preferably designated at the H900 condition to minimizethe thickness of the transverse support member 12 and to provide thedesired resistance to bending and elongation. PH 13-8 MO condition H950material can be used where even greater material strength is required.Where very low magnetic permeability is desired, the preferred materialis Inconel 718, UNS N07718, available from various sources, includingEarl M. Jorgensen, Inc. It is also contemplated, however, that thesupport member 40 could be made from any rigid material that providesadequate support for the conductor pins 20 when subjected to extremelyhigh pressure differentials. Further, the use of an insulativestructural material such as XYCOMP™ composite material available fromGreene Tweed & Co., Inc. (“GT”), located in Kulpsville, Pa. could beused to fabricate the support member 40, to enhance electricalperformance. Also, ceramic materials such as transformation toughenedzirconia (“TTZ”), alumina and other ceramics could be used forfabrication of the support member 40.

Those of ordinary skill in the art will recognize the thickness of thetransverse support member 40 can be varied to suit the specific strengthrequired in a given application, depending on the pressure differentialacross the connector 10 and the material from which the transversesupport member 40 is constructed. It is preferred that the transversesupport member 40 extend radially to contact the bulkhead 12, such thatthe transverse support member 40 provides support to the connector 10across its entire diameter, thereby improving the resistance of theconnector 10 to high pressure differentials across the bulkhead 12. Theconductor pins 20 pass through the passages 42 in transverse supportmember 40 thereby providing a conductive path through the connector 10for passage of electrical current. The number of conductor pins 20 mayvary from one to several, depending on the needs of the particularapplication. However, as those of ordinary skill in the art willrecognize, there is no real upper limit on the number of conductor pins20 that could be accommodated. Of significance in determining the numberof conductor pins 20 that can be accommodated in the connector 10 is thegauge or diameter of each conductor pin 20.

The insulating sleeves 50 each include a base portion 52 having at leastone circumferential groove 54 therein. The groove 54 assists inretaining the insulating sleeve 50, the conductor pin 20 and thetransverse support member 40 to the connector body 30. Alternatively,the insulating sleeve 50 could be fixedly attached to the support member40, eliminating the need for the groove 54 (see, for example, the fifthembodiment 410 electrical connector discussed below herein). The baseportion 52 engages the conductor pin shoulder 24, and transfers loadfrom the conductor pin 20 to the support member 40, thus helping toprovide stability to the conductor pins 20 at elevated temperature andpressure conditions, at which the material of the conductor body 30 maybe subject to creep.

The insulating sleeves 50 may be fabricated from a variety of materials,including many polymeric materials like PEEK (polyetheretherketone),PEEK-HT (higher glass transition temperature PEEK), PEKK(polyetherketoneketone), PAEK (polyaryletherketone), PPS (polyphenylenesulfide), PBI (polybenzimidazole), LCP (liquid crystal polymer),structural glasses, polycrystalline diamond, VESPEL™ or AURUM™polyimides, PAI (polyamidimide), PEI (polyetherimide), XYCOMP™composites (or similar PEEK and glass fiber composites) or any number ofother alternatives. Unfilled and filled grades of these and otherpolymers are also applicable. Fillers would include but are not limitedto glass fibers, glass beads, aramyd fibers, ceramics, and otherinsulative compounds. Thermoset materials are also possible in eitherunfilled or filled grades. Composites of all the polymers listed abovecombined with glass beads or glass fibers could be used to fabricate theinsulating sleeves 50. The glass fibers could be of varying length, upto and including being continuous. Further, ceramic materials such asTTZ, Alumina, Silicone Dioxide, machineable ceramics like those offeredfrom Macor, synthetic sapphire, and other electrically insulativestructural ceramics are envisioned. Additionally, ceramic or polymericcoated metallic materials (where the coating provides electricalisolation and the metal substrate provides structural rigidity and creepresistance) could be used. It is expected that for the ultimate pressureand temperature capabilities that ceramic materials will be used in thepreferred embodiments.

The molded connector body 30 surrounds at least a central portion of theconductor pins 20 and electrically insulates the conductor pins 20 fromthe bulkhead. To permit enhanced sealing between the connector 10, andin particular the connector body 30, and the bulkhead 12, the connectorbody 30 preferably includes at least one circumferential groove 32 in anexternal surface thereof. A seal ring 34, preferably an O-ring, eitheralone or combined with a backup ring, is situated in the circumferentialgroove 32 so as to form a seal between the connector body 30 and thebulkhead 12. The seal ring 34 is preferably constructed from Compounds#926 or #780, available from GT. In the highest temperatureapplications, GT's #605 CHEMRAZ® elastomer material is preferred. It iscontemplated that more than one circumferential groove 32 and seal ring34 may be employed without departing from the scope and spirit of theinvention. Additionally, it is contemplated that the connector 10 couldbe employed without any circumferential grooves 32 and seals 34, theconnector body 30 providing a seal against the bulkhead 12, or thatalternative devices for sealing (not shown) could be used, including GTrings, Advancap seals, ENERCAP® seals, metal spring energizednon-elastomer seals (MSE™), Polypak seals, elastomeric andnon-elastomeric cup seals etc.

The connector body 30 preferably is constructed from a polymericmaterial, preferably insulative thermoplastic, and most preferably frompolyetherketone (PEK), produced by Victrex Ltd. and sold by Greene,Tweed & Co. under the trademark ARLON 2000®. This material is mostpreferable because of its ability to maintain dimensional stability andconsistent mechanical properties at high temperatures (in excess of 400°F.). It is contemplated that other polymeric materials, such as ULTEM,PAEK, PEEK, or PEKK, PPS, PBI, LCP, or PAI may be employed withoutdeparting from the scope and spirit of the invention.

With reference now to FIG. 2, a second embodiment electrical connector110 is generally similar to the first embodiment electrical connector 10with the key exceptions that the transverse support member 40 isreplaced with an electrically insulative support member 140, and ashoulder 124 of conductor pin 120 bears directly against the insulativesupport member 140 (rather than against the intermediate insulatingsleeve 50 as shown in the first embodiment electrical conductor 10). Aninsulating sleeve 150 is located on the conductor pin 120 on the lowpressure side of the insulative support member 140. In general, elementsof the second embodiment electrical connector 110 are assigned referencenumbers incremented by 100 above corresponding elements of the firstembodiment electrical connector 10. For example, the second embodimentconnector 110 comprises seal rings 134 corresponding to the seal rings34 of the first embodiment connector 10. With the exceptions notedabove, the structure and operation of the second embodiment electricalconnector 110 is generally similar to the structure and operation of thefirst embodiment electrical connector 10, and it is not necessary todescribe the second embodiment 110 in further detail.

With reference now to FIG. 3, a third embodiment of the electricalconnector 210 is generally similar to the first embodiment electricalconnector 10, with the key exception that a single pin 220 is shown. Ingeneral, elements of the third embodiment electrical connector 210 areassigned reference numbers incremented by 200 above correspondingelements of the first embodiment electrical connector 10. With theexceptions noted above, the structure and operation of the thirdembodiment electrical connector 210 is generally similar to thestructure and operation of the first embodiment electrical connector 10,and it is not necessary to describe the third embodiment 210 in furtherdetail.

With reference now to FIG. 4, a fourth embodiment of the electricalconnector 310 is generally similar to the first embodiment electricalconnector 10, with the key exceptions that a single pin 320 is shown, atransverse support member 340 includes a threaded portion 344 adapted toengage mating threads in a bulkhead 312, and a connector body 330 isprovided with a coupling ridge 336 to retain a female receptaclethereon. In general, elements of the fourth embodiment electricalconnector 310 are assigned reference numbers incremented by 300 abovecorresponding elements of the first embodiment electrical connector 10.With the exceptions noted above, the structure and operation of thefourth embodiment electrical connector 310 is generally similar to thestructure and operation of the first embodiment electrical connector 10,and it is not necessary to describe the fourth embodiment 310 in furtherdetail.

With reference now to FIGS. 5A, 5B and 5C, first, second and thirdembodiments of coaxial electrical connector subassemblies 510, 510′ and510″ may be incorporated into additional embodiments of the presentinvention. For example, in FIG. 5C the third embodiment coaxialelectrical connector subassembly 510″ is shown incorporated into a fifthembodiment hermetic electrical connector 410. The fifth embodimentconnector 410 is generally similar to the first embodiment electricalconnector 10, comprising a plurality of pins 420, a connector body 430,a transverse support member 440 and insulating sleeves 450. The outercircumference of the transverse support member 440 of the fifthembodiment connector 410 seats against a pressure bearing ledge 414 totransfer load from the molded connector body 430 and the conductor pins420 to the bulkhead 412. Unlike the first embodiment connector 10, thefifth embodiment connector 410 further comprises a coaxial electricalconnector, more specifically comprising the third embodiment coaxialelectrical connector subassembly 510″.

Each of the first, second and third embodiment coaxial electricalconnector subassemblies 510, 510′ and 510″ comprises an electricallyconductive outer sleeve 512 and a conductor pin 520. The conductor pin520 is supported within the outer sleeve 512 by a connector body 530, afirst support member 540 and a second support member 545. The outersleeve 512 includes a first section 512 a, a second section 512 b, athird section 512 c and a fourth section 512 d. Outer and innerdiameters of the first through fourth sections 512 a-512 d decrease insequence from the first section 512 a to the fourth sections 512 d,forming two pressure bearing shoulders 514 a and 514 b. The conductorpin 520 has a high pressure end 520 a and a low pressure end 520 b aswell as a middle portion 520 c. The middle portion 520 c is providedwith a larger outer diameter than the diameters of either the highpressure end 520 a or low pressure end 520 b. Thus, shoulders 524 areformed at each end of the middle portion 520 c. The connector body 530bears against the first support member 540, and the first support member540 in turn bears against both the first pressure bearing shoulder 514 aand the second support member 545. The second support member 545 issupported by the second pressure bearing shoulder 514 b. Presentlypreferred materials of construction for the first and second supportmembers are a ceramic material such as Alumina for the first supportmember and a polymeric material, such as polytetrafluoroethylene(“PTFE”) for the second support member. This construction is required tomaintain proper impedance values along the length of the coaxialconnector subassembly.

With particular reference now to FIG. 5C, the third embodiment coaxialconnector subassembly 510″ is electrically isolated from the supportmember 440 by insulating sleeve 450′. The third embodiment coaxialsubassembly 510″ bears against the upper structural portion 450″ of theinsulating sleeve 450′ at the shoulder 414 a. The insulating sleeve 450′may be constructed as separate components as shown or as one continuouselement. The coaxial connector subassemblies 510, 510′ or 510″ need notbe incorporated into an electrical connector having both pin and coaxialelectrical connectors. The coaxial connector subassemblies could bemolded singularly or in combination with additional coaxial connectorsubassemblies into complete electrical connectors. Further, thisinventive construction could be extended to triaxial, quadraxial or anynumber of concentric alternating electrically conductive and insulatinglayers.

With reference now to FIG. 6, a sixth embodiment of the electricalconnector 610 is generally similar to the first embodiment electricalconnector 10, with the key exceptions that there exists a dovetailretention feature 660 interlocking the transverse support member 640 tothe molded connector body 630. The dovetail retention feature 660 is agenerally annular ring that extends generally axially from thetransverse support member 640 and includes an enlarged distal end. Thedovetail retention joining method allows the molded connector body 630to be positively locked to the transverse support member 640 to producea stronger joint than other types of joining methods. The presentinvention is not limited to foregoing joining method. For instance, thedovetail retention feature could have discrete segments instead of beingannular (not shown). Further alternatives to the dovetail retentionfeature are the dado joining method, the lap joining method, and themortise and tenon joining method. Other alternatives are well known tothose of ordinary skill in the art. The sixth embodiment electricalconnector 610 also includes two alignment holes 670 a, 670 b foraligning the transverse support member 640 in relation to the bulkhead612. In addition, the conductor pins 620 of the sixth embodimentelectrical connector 610 are different from the conductor pins 20 of thefirst embodiment electrical connector 10. The high pressure and lowpressure ends 620 a, 620 b of the sixth embodiment electrical connectorare open ended compared to the closed round shape of the high pressureand low pressure ends 20 a,20 b of the first embodiment electricalconnector. In general, elements of the sixth embodiment electricalconnector 610 are assigned reference numbers incremented by 600 abovecorresponding elements of the first embodiment electrical connector 10.With the exceptions noted above, the structure and operation of thesixth embodiment electrical connector 610 is generally similar to thestructure and operation of the first embodiment electrical connector 10,and it is not necessary to describe the sixth embodiment in furtherdetail.

With reference now to FIG. 7, a seventh embodiment of the electricalconnector 710 is generally similar to the first embodiment electricalconnector 10, except for the differences noted below. The seventhembodiment electrical connector 710 includes a dovetail retentionfeature 760 interlocking the transverse support member 740 to the moldedconnector body 730 as described above in connection with the sixthembodiment electrical connector 610 except that it is disc shaped asopposed to annular shaped. Two coaxial alignment holes 770 a, 770 b areappositively disposed on the transverse support member 740 for thepurpose of insertion and removal into the bulkhead. The seventhembodiment electrical connector 710 also includes a dowel pin 780 foraligning the transverse support member 740 to the bulkhead 712. Theseventh embodiment electrical connector 710 includes a two-pieceinsulating sleeve insert 750 a, 750 b compared to the one-piece insert50 of the first embodiment electrical connector 10. The first insulatingsleeve insert 750 a is an elongated generally thin tubular member thatsurrounds the pin. The second insulating sleeve insert 750 b is also anelongated tubular member but it is slightly thicker than the firstinsert 750 a. The second insert 750 b engages the conductor pin shoulder724. As compared to the first embodiment electrical connector 10, thetransverse support member 740 of the seventh embodiment electricalconnector 710 includes a base portion 740 a that extends through themolded connector body 730 to its rear surface thereof. The base portion740 a of the transverse support member 740 of the seventh embodimentelectrical connector 710 includes circumferential grooves 745. Thegrooves 745 assist in retaining the transverse support member 740 to themolded connector body 730. In general, elements of the seventhembodiment electrical connector 710 are assigned reference numbersincremented by 700 above corresponding elements of the first embodimentelectrical connector 10. With the exceptions noted above, the structureand operation of the seventh embodiment electrical connector 710 isgenerally similar to the structure and operation of the first embodimentelectrical connector 10, and it is not necessary to describe the seventhembodiment electrical connector 710 in further detail.

With reference now to FIG. 8, an eighth embodiment of the electricalconnector 810 is generally similar to the first embodiment electricalconnector 10, except for the differences noted below. The eighthembodiment electrical connector 810 includes a dovetail retentionfeature 860 interlocking the transverse support member 840 to the moldedconnector body 830 as described above in connection with the sixthembodiment electrical connector 610. The eighth embodiment electricalconnector 810 also includes a dowel pin 880 for aligning the transversesupport member 840 to the bulkhead 812. The bulkhead 812 and thetransverse support member 840 include mating sloped edges for thepurpose of ease of insertion in a deep blind hole bulkhead. In general,elements of the eighth embodiment electrical connector 810 are assignedreference numbers incremented by 800 above corresponding elements of theninth embodiment electrical connector 910. With the exceptions notedabove, the structure and operation of the eighth embodiment electricalconnector 810 is generally similar to the structure and operation of thefirst embodiment electrical connector 10, and it is not necessary todescribe the eighth embodiment electrical connector 810 in furtherdetail.

With reference now to FIG. 9, a ninth embodiment of the electricalconnector 910 is generally similar to the first embodiment electricalconnector 10, except for the differences noted below. The ninthembodiment electrical connector 910 includes a dovetail retentionfeature 960 interlocking the transverse support member 940 to the moldedconnector body 930 as described above in connection with the seventhembodiment electrical connector 710. The ninth embodiment electricalconnector 910 also includes an insulating sleeve 950 that is a taperedpre-machined boss insert. The insulating sleeve 950 which is generallyfrusto-conically shaped and is generally thicker in diameter than theinsulating sleeve 50 of the first embodiment electrical connector. Theshoulder 924 on each conductor pin 920 is correspondingly sized to theinsulating sleeve 950. In general, elements of the ninth embodimentelectrical connector 910 are assigned reference numbers incremented by900 above corresponding elements of the first embodiment electricalconnector 10. With the exceptions noted above, the structure andoperation of the ninth embodiment electrical connector 910 is generallysimilar to the structure and operation of the first embodimentelectrical connector 10, and it is not necessary to describe the ninthembodiment electrical connector 910 in further detail.

With reference now to FIG. 10, a tenth embodiment of the electricalconnector 1010 is generally similar to the ninth embodiment electricalconnector 910, except for the differences noted below. The insulatingsleeve 1050 included in the tenth embodiment electrical connector 1010is generally cylindrically shaped with a threaded end on the lowpressure side. The insulating sleeve 1050 is threaded into thetransverse support member 1040. In general, elements of the tenthembodiment electrical connector 1010 are assigned reference numbersincremented by 1000 above corresponding elements of the ninth embodimentelectrical connector 90. With the exceptions noted above, the structureand operation of the tenth embodiment electrical connector 1010 isgenerally similar to the structure and operation of the ninth embodimentelectrical connector 910, and it is not necessary to describe the tenthembodiment electrical connector 1010 in further detail.

With reference now to FIG. 11, an eleventh embodiment of the electricalconnector 1110 is generally similar to the ninth embodiment electricalconnector 910, with the key exception that the insulating sleeve 1150 inthe eleventh embodiment electrical connector 1110 is a two-piece insert1150 a, 1150 b. The two-piece insert has a first insert 1150 aconstructed of a relatively high strength insulating material and asecond insert 1150 b constructed of a relatively lower strengthinsulating material. The high strength material could be a ceramic orother high strength materials known to people of ordinary skill in theart. The lower strength material could be a polymeric material or otherlower strength material known to people of ordinary skill in the art.The second insert 1150 b is a generally elongated relatively thin tubewhile the first insert 1150 a is disc shaped and surrounds the baseportion of the second insert 1150 b, engaging the shoulder 1124 of theconductor pin 1120. In general, elements of the eleventh embodimentelectrical connector 1110 are assigned reference numbers incremented by1100 above corresponding elements of the first embodiment electricalconnector 10. With the exceptions noted above, the structure andoperation of the eleventh embodiment electrical connector 1110 isgenerally similar to the structure and operation of the ninth embodimentelectrical connector 910, and it is not necessary to describe theeleventh embodiment electrical connector 1110 in further detail.

With reference now to FIG. 12, a twelfth embodiment of the electricalconnector 1210 is generally similar to the first embodiment electricalconnector 10, except for the differences noted below. The twelfthembodiment electrical connector 1210 includes a dovetail retentionfeature 1260 interlocking the transverse support member 1240 to themolded connector body 1230, as described above in connection with thesixth embodiment electrical connector 610. The twelfth embodimentelectrical connector 1210 includes a dovetail feature 1260 which isgenerally L-shaped in cross section and has a slightly tapered radiallyinward edge. The insulating sleeve of the twelfth embodiment electricalconnector is a two-piece insert 1250 a, 1250 b essentially of the typedescribed in connection with the seventh embodiment electrical connector610. The twelfth embodiment electrical connector 1210 also includes adowel pin 1280 for alignment to the bulkhead 1212. The upper portion ofthe dowel pin 1280 sits in a slot 1290. The slot 1290 allows the dowelpin 1280 to be properly received, thereby allowing for proper alignmentof the transverse support member 1240 in relation to the bulkhead 1212.The twelfth embodiment electrical connector 1210 also includes a hole1270 for retention to the bulkhead. The upper left portion of thebulkhead 1212 includes another slot 1235 for aligning a member (notshown) which mates with the pins 1220. In general, elements of thetwelfth embodiment electrical connector 1210 are assigned referencenumbers incremented by 1200 above corresponding elements of the firstembodiment electrical connector 10. With the exceptions noted above, thestructure and operation of the twelfth embodiment electrical connector1210 is generally similar to the structure and operation of the firstembodiment electrical connector 10, and it is not necessary to describethe twelfth embodiment electrical connector 1210 in further detail.

The method of making the connector 10 is discussed hereinbelow. Forpurposes of clarity, the method is described with reference to the firstpreferred embodiment connector 10 shown in FIG. 1 and is intended to beillustrative of the method of making all embodiments of the presentinvention. In preparation for placement into an injection mold (notshown), the conductor pins 20, insulating sleeves 50 and transversesupport member 40 are preferably heated to at least approximately 200degrees Fahrenheit, and preferably to approximately 400 degreesFahrenheit, prior to injecting polymeric material into the mold. It iscontemplated, however, that the step of heating the conductor pins 20,insulating sleeves 50 and transverse support member 40 could occureither before or after placing the conductor pins 20, insulating sleeves50 and transverse support member 40 within the injection mold.

The conductor pins 20, insulating sleeves 50 and transverse supportmember 40 are placed within the injection mold having the desiredfinished shape of the connector body 30. Preferably substantially allair is removed from the mold prior to injecting the polymeric materialinto the mold. This is accomplished through evacuation of the mold usingconventional apparatus such as a vacuum pump (not shown).

A polymeric material, most preferably PEK is injected into the injectionmold for creating the connector body 30 which surrounds the conductorpins 20. Preferably the polymeric material is heated to at least 500degrees Fahrenheit, and more preferably to about 700 degrees Fahrenheit,prior to injecting the polymeric material into the mold. The polymericmaterial is preferably injected into the mold at a pressure of at least7500 pounds per square inch, and most preferably about 18,000 pounds persquare inch. Following the injection step, the connector 10 ispreferably heated to relieve stress in the polymeric material, thusminimizing the risk that post-cooling contraction of the connector body30 will distort the conductor pins 20. It is preferred that the heatingis to a minimum of the rated operating temperature of the connector 10,about 400-500 degrees Fahrenheit for application of the connector 10 ina downhole well.

Following the stress relief step, the entire assembly is permitted tocool, whereby the polymeric material of the connector body 30 shrinksand forms a bond with the conductor pins 20 and the insulating sleeve50, capturing the circumferential grooves 22 and 52, respectively. Thepolymeric material also effectively captures the transverse supportmember 40 by bonding therewith, thus completing the supporting structurefor the conductor pins 20.

The connector body 30, conductor pins 20, insulating sleeves 50 andtransverse support member 40 are removed from the injection mold and theconnector body 30 is machined to provide any features not specificallymolded into the connector body 30, or to refine features that have beenmolded in.

From the foregoing it can be seen that the present invention comprises ahermetic electrical connector particularly well suited for service inhigh temperature and high pressure environments. It will be appreciatedby those skilled in the art that changes could be made to theembodiments described above without departing from the broad inventiveconcept thereof. It is understood, therefore, that this invention is notlimited to the particular embodiments disclosed.

1. A hermetic pressure connector for providing a pressure-tight,electrically conductive connection through a hole in a bulkhead, theconnector comprising: a transverse support member having a high pressureside and an opposite low pressure side with a passage extending throughthe transverse support member between the opposite sides; a conductorpin having an axial portion extending through the passage; an insulatingsleeve surrounding at least the axial portion of the conductor pinthereby electrically insulating the transverse support member from theconductor pin, wherein the insulating sleeve is a two-piece insert,wherein the two-piece insert has a first piece that is located on thehigh pressure side and is constructed of a ceramic and a second piecethat is located on the low pressure side and is constructed of apolymeric material; a molded connector body surrounding at least acentral portion of the conductor pin at least at one of the high and lowpressure sides to thereby mechanically support the conductor pin in thepassage, the molded connector body being directly sealingly engaged withthe conductor pin, the insulating sleeve and the transverse supportmember.
 2. The hermetic pressure connector of claim 1, wherein thetransverse support member includes a plurality of passages and there isa corresponding plurality of conductor pins having axial portionsextending through respective passages, each conductor pin including theinsulating sleeve surrounding the axial portion.
 3. The hermeticpressure connector of claim 1, wherein the transverse support member isconstructed of a metallic material.
 4. The hermetic pressure connectorof claim 1, wherein the conductor pin includes a circumferentialinterlocking member encased by the molded connector body forinterlocking the conductor pin and the molded connector body.
 5. Thehermetic pressure connector of claim 4, wherein the circumferentialinterlocking member includes a circumferential groove formed in theconductor pin.
 6. The hermetic pressure connector of claim 1, whereinthe transverse support member includes a dovetail retention featureinterlocking the transverse support member to the molded connector body.7. The hermetic pressure connector of claim 1, wherein a circumferentialgroove is formed in an external surface of the molded connector body. 8.The hermetic pressure connector of claim 1, wherein the molded connectorbody further includes a coupling ridge to retain a receptacle thereon.9. The hermetic pressure connector of claim 1, wherein the conductor pincomprises beryllium copper.
 10. The hermetic pressure connector of claim1, wherein the molded connector body surrounds the central portion ofthe conductor pin beyond the passage at the high pressure side.
 11. Thehermetic pressure connector of claim 1, wherein the molded connectorbody surrounds the central portion of the conductor pin beyond thepassage at the low pressure side.
 12. The hermetic pressure connector ofclaim 1, wherein the molded connector body extends beyond the transversesupport member at least at one of the high and low pressure sides. 13.The hermetic pressure connector of claim 1, wherein the transversesupport member comprises a plate, at least a portion of which isembedded in the molded connector body.
 14. The hermetic pressureconnector of claim 13, wherein the plate has an outside diameter that issubstantially equal to an outside diameter of the molded connector body.15. The hermetic pressure connector of claim 1, wherein the transversesupport member has an outside diameter that is substantially equal to anoutside diameter of the molded connector body.
 16. The hermetic pressureconnector of claim 1, wherein the molded connector body comprises apolymeric material.
 17. The hermetic pressure connector of claim 16,wherein the conductor pin and transverse support member areinsert-molded with the polymeric connector body.